Marathon rebuild

[BBBHC]

Originally Posted by Newbuggyboy

The problem is the leads seem to be a double thread bolt. One side goes into motor. Then there is a nut. Then another thread to put the wire on. Followed by another nut. Does anyone know how these work? Can you explain how to remove them? I tried a wrench and a socket. But the the two nuts were different sizes. The outermost was 1/2". The inner was larger than 1/2", but the 17/32" or 9"/16" didn't fit. Maybe just that one was buggered.

The photo is not my motor but shows the same type of lead.

I can't remember the sizes on those nuts. But yes, they are both nuts. You need to "double wrench" them. If you turn the bolt inside the motor, you will ruin the motor and at least need to take it to get rebuilt.

[Newbuggyboy]

Originally Posted by BBBHC

I can't remember the sizes on those nuts. But yes, they are both nuts. You need to "double wrench" them. If you turn the bolt inside the motor, you will ruin the motor and at least need to take it to get rebuilt.

That's what it looked like would happen inside the motor if you turned the "stud" or "base." I got a new set of wrenches today. Well see what happens.

[Newbuggyboy]

Those new wrenches worked great. Forgot to take a picture of the set. It was a harbor freight special. Snub (small not very big) wrench one side open other closed. Set of sea, and metric. $6.99.

Those motor bolts came right off! Now my new cables. I'm thinking 4 guage. The last set of 2 guage I got seem very inflexible. And not friendly to work with. But, explain why if you think differently.

[cgtech]

Possibly the cable material was standard automotive style cable, not "high strand count welding cable"? The difference would be easily noticable if you could see the strands inside. Regular cable would have 16-40 larger strands, good welding cable would have 240-360 tiny strands inside, and is much more flexible.

[Newbuggyboy]

I got them off ebay $39

EZGO RXV Golf Cart Car 2 Gauge HD NEON GREEN BRAIDED Battery Cables
BUILT AND MADE IN THE U.S.A

EACH CABLE IS HYDRAULIC CRIMPED WITH 5/16" TINNED COPPER LUGS ON EACH END.

EACH CABLE IS BUILT FROM CENTER TO CENTER OF LUG HOLES.
CABLE USED FOR BUILDING IS HEAVY DUTY EPDM 105C WELDING CABLE MADE IN U.S.A.

EACH CRIMPED END IS COVERED IN 3:1 HEAT SHRINK
STRANDING IS: 624 STRANDS OF BARE COPPER
RESISTANCE TO (FLAME, OIL, GREASE SOLVENTS, OZONE AND ABRASION.(ROHS COMPLIANCE)

AMPS: 200
600 VOLTS.
4 X 12 INCHES
1 x 24 INCHES
and
1 x 34 INCHES

IF YOU WANT THIS SAME SET IN RED OR BLACK BRAID
JUST ADD A NOTE IN THE ORDER TO YOUR COLOR U WANT.

[Newbuggyboy]

For the marathon I count 13 cables. The ebay seller has a set of 14. Am I missing one?

And how is my color coding scheme?

6 x black or black neon
5 of those are for battery to battery
1 from pack - to controller (B-)

4 X neon green
4 of all these go to the motor
1 from the F/R right side to S1
1 from F/R left side to S2
1 from controller B+ to A1
1 from controller A2 to A2

3 X Red or neon red
Controller
1 of those is from the Pack + to the controller
1 from F/R left to controller (A2)
1 from F/R to controller (M-)

[Newbuggyboy]

I think I found 14. It goes from solenoid to B+ on controller.

[LukeL]

Originally Posted by Newbuggyboy

I think I found 14. It goes from solenoid to B+ on controller.

Yes- that’s an important one. [emoji1303]

[Newbuggyboy]

Out with the old. In with the new.

[Newbuggyboy]

The shocks probably were not made in fort wayne indiana. They do have a cool holographic sticker on them.

I'm so excited the front cowl kit came. This was a bugger to find.